Controller for a motorized awning system

Abstract

A motor controller for a drive motor of an RV awning system, increases the voltage provided to the motor from the RV power supply to a boosted voltage, to increase the speed of the motor and thereby reduce the amount of time required to deploy or retract the awning. The motor controller includes a microprocessor control unit that uses a PWM control signal to linearly increase the current to the drive motor to achieve a soft start for the motor and reduce the risk of an overcurrent condition. The motor controller is configured to be added to an existing awning switch to easily increase the operating speed of an existing awning drive motor. The motor controller includes a housing with a flange that rests on the lower ledge of the switch opening formed in the outer wall of the RV.

What is claimed is: 
     
         1 . An improvement for a recreational vehicle (RV) having an electrical system and an RV power supply to power the electrical system at an RV voltage, and one or more motorized awning systems, each awning system having an extendable awning, a motor for extending the awning, and a user-actuated switch for activating the motor, the improvement comprising a motor controller connecting the RV power supply, the motor and the user-actuated switch, the motor controller including:
 a booster circuit connected to said power supply and configured to increase the RV voltage to a boosted voltage signal at a booster output;   an output control circuit connecting the booster output to the drive motor, the output control circuit controlled by a pulse-width modulated (PWM) signal to control the current provided to the output motor; and   a microprocessor control unit (MCU) connected to the user-actuated switch and configured to provide the PWM signal to the output control circuit when and as long as the switch is actuated by the user, wherein the PWM signal is adapted to linearly increase the current from zero amps to a maximum current for the RV electrical system within a predetermined time interval and to maintain the maximum current during the operation of the drive motor.   
     
     
         2 . The improvement of  claim 1 , wherein:
 the MCU generates an enable signal when and as long as the switch is actuated by the user; and   said booster circuit includes a microprocessor configured to enable the booster circuit only as long as the enable signal is received from said MCU.   
     
     
         3 . The improvement of  claim 2 , wherein:
 the motor controller further includes a current measurement circuit that measures the current of the boosted voltage signal at the booster output, compares the measured current to a maximum allowable current and generates a control signal provided to the MCU if the measured current exceeds the maximum allowable current; and   said MCU is configured to terminate the PWM signal provided to the output control circuit to disable the output control circuit and to terminate the enable signal provided to the microprocessor of the booster circuit to disable the booster circuit.   
     
     
         4 . The improvement of  claim 2 , wherein:
 the motor controller further includes a thermistor that generates a temperature signal indicative of the temperature of one or more components of the motor controller; and   the MCU is configured to compare the temperature signal to a threshold temperature value and to terminate the PWM signal provided to the output control circuit to disable the output control circuit and to terminate the enable signal provided to the microprocessor of the booster circuit to disable the booster circuit.   
     
     
         5 . The improvement of  claim 1 , wherein the predetermined time interval is one (1) second. 
     
     
         6 . An improvement for a recreational vehicle (RV) having a power supply and electrical system, and one or more motorized awning systems, each awning system having an extendable awning, a drive motor for extending the awning, and a user-actuated switch for activating the motor in which the switch is mounted within a switch opening formed in an outer wall of the RV, the improvement comprising a motor controller including:
 wiring to connect to the motor controller to the power supply, the switch and the drive motor;   a microprocessor control unit (MCU) and electrical circuits configured to control the electrical power provided to the drive motor; and   a housing containing the MCU and electrical circuits, the housing including a mounting bracket at a top end of the housing that is configured to rest on a lower ledge of the switch opening when the switch is mounted within the switch opening.   
     
     
         6 . The improvement of  claim 5 , wherein said housing includes radiator fins projecting from an outer surface of the housing to dissipate heated generated by the MCU and electrical circuits within the housing.